Strange problem with rotary switch stop washers

[Aural Robert]

The two rotary switches for the volume controls have little stop washers to set the stops. For some reason, mine doesn't sit flat on the body, which causes the switch to mount cock-eyed to the sub-panel.

I know this because I built it and when I put the knobs on, they weren't centred on the numbered dial on the overlay. Subsequent disassembly and investigation has brought me back to the Mother Ship for advice and recommendations.

I've attached a photo showing the issue. I do have a mechanical aptitude and this is not my first build. I can't figure out wtf is going on here, the little tab seems to be too long.

I guess I can file it down (or use a dremel) but thought I'd post here first to make sure I'm not just missing something or messing up somehow.

TIA. Stay safe.

Aural Robert
... only an expert can deal with the problem ...

[Thermioniclife]

Hello, I think you should have 2 stop washers with this switch.
One will have a shorter tab, place this one on shaft first in the correct position then the longer one on top and also in the correct position. this will set the switch up for the correct amount of positions and orientation on the trim bezel.
Hope this is of help.

[Aural Robert]

Yes there are two washers, with different diameters. This is the smaller one that has to go underneath the larger one, and this is the one with the shorter tab as suggested. I only had the smaller one on when I took the photo.

Thanks.

[Paul Birkeland]

Are you having the same issue with both switches?

Could you take a photo of your switch similar to the one in the manual with all the parts laid out?

-PB

[Aural Robert]

 Yep, exactly the same problem with both switches. Photos attached.

Thanks Paul.

[Paul Birkeland]

I will contact Electro-switch and ask them what's going on with the hardware.

Since you are likely very interested in continuing with your build, I would get a small straight file and file down the shoulder a little bit so more of the pokey bit goes into the hole in the switch body. 

[Aural Robert]

Thanks Paul, things went well and the build is finished. It sounds AMAZING I have HD 600's and it's time to start saving for the 800's I think.

I've posted a few pics of the new amp and it's current location to optimize it's use. Next up is my Raspberry Pi streamer.

Stay safe all you Bottleheads!@@

Aural Robert
... 'Cause life is sweet, when you hit the mainline ...

[Paul Birkeland]

The first super ancient prototype that I built of the Mainline circuit was purple on a white base

The white base is long gone, but the purple top plate and white transformer cover live on!

[Karl5150]

That is sharp. I've never thought of painting the lam stack, very nice. Was it difficult to prep it enough to paint?
Karl

[oguinn]

That looks really nice. Any interest in contributing some photos to my gallery site?

[Aural Robert]

Karl - it was mainly elbow grease. I started by sanding the edges with emery cloth, then multiple coats of primer and sanding to get the surface flush and the laminate lines to disappear. And then a few coats of the final colour. I've done this on all my Bottlehead gear.

I generally take longer to prep and paint than I do with my actual build. I'm too picky when it comes to having a perfect finish.

[Aural Robert]

Jameson, I will happily contribute. Any specifics as to image size and quality, # of photos etc? Let me know and I'll set up some shots. I have an EOS 60D so have a lot of options available.

[oguinn]

A couple things are helpful: a handful of good sized images stored on Imgur or another storage service, and a write up with any customization or details you’d like to share.

Also, PB - I got your submission and will post this week. Thank you!